I think some people use the words "allergy", "sensitivity", and "irritation" interchangeably, which is incorrect. That being said, what were their complaints? When you say "break out", do you mean acne bumps or rash? Some people are more sensitive to the higher alkalinity of hand made soaps, some people find high coconut oil formulas drying or irritating, certain "botanicals" can be allergens (like Chamomile, which is in the ragweed family), many people are allergic to fragrance...the list goes on and on. There's someone allergic to everything. Are you sure your soaps are not lye heavy? That could certainly cause irritation. What is your "standard" CP recipe? It's easier to help narrow down the problem if we have more information.